USER INSTRUCTIONS

Limitorque Actuation Systems L120 Series

For L120-10 through L120-40
FCD LMENIM1201-01 07/06

Installation Operation Maintenance

Experience In Motion

Limitorque Actuation Systems L120 Series

FCD LMENIM1201-01 07/06

Contents
1 2 Introduction 1.1 Purpose 1.2 User Safety Product Capabilities and Features 2.1 Initial Inspection and Storage Instructions 2.2 Product Identification 2.3 Inspection and Recording 2.4 Storage Procedures 2.4.1 Short-Term Storage (less than 1 year) Actuator Weights Installation Instructions 4.1 Safety Precautions 4.2 Safety Practices 4.3 Initial Actuator Preparation 4.3.1 Mounting Base 4.3.2 Stem Acceptance 4.4 Torque Switch 4.4.1 Setting Torque Switch 4.4.2 Balancing Torque Switch 4.5 Geared Limit Switch 4.5.1 Setting Limit Switch 4.5.2 Setting Procedure (Refer to Figure 4.2) 4.5.3 Combination of Contacts (Refer to Figure 4.2) 4.6 Position Indication 4.6.1 Local position indication 4.6.2 Remote Position Indication 4.7 Optional Side-Mounted Handwheel 4 4 4 5 5 5 7 7 7 8 9 9 9 10 10 10 11 11 12 12 12 13 14 14 14 15 16

3 4

Limitorque Actuation Systems L120 Series

FCD LMENIM1201-01 07/06

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Operation 5.1 Electrical Start-up 5.2 Manual Operation 5.3 Motor Operation 5.4 Torque and Travel Limiting Maintenance 6.1 Lubrication 6.1.1 Lubrication Inspection 6.1.2 Factory Lubricant 6.2 Minimum Lubricant Qualities Required 6.3 Disassembly and Reassembly 6.4 Disassembly of the L120-10, 20, and 40 6.5 Drive Sleeve and Housing Cover Disassembly 6.6 Torque Nut Disassembly (Drive 1 Option) 6.7 Thrust Base Disassembly (Drive 2 Option) 6.8 Stem Nut Replacement Thrust Base Applications 6.9 Reassembly 6.9.1 Declutch Assembly (L120-10) 6.9.2 Declutch Assembly (L120-20/40) (Refer to Figure 6.3) 6.9.3 Install the Motor (Refer to Figure 5.2) 6.9.4 Lubrication Procedure 6.9.5 Install Geared Limit Switch, Torque Switch and Finish Assembly How to Order Parts Regulatory Information

19 19 20 25 25 26 26 26 27 27 28 28 29 29 30 30 31 32 32 33 33 33 34 35

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Limitorque Actuation Systems L120 Series

FCD LMENIM1201-01 07/06

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Introduction
1.1 Purpose
This Installation and Maintenance Manual explains how to install and maintain the L120-10, L120-20, and L120-40 actuators. Information on installation, disassembly, reassembly, lubrication, and parts is provided.

1.2 User Safety

Safety notices in this manual detail precautions the user must take to reduce the risk of personal injury and damage to the equipment. The user must read and be familiar with these instructions before attempting installation, operation, or maintenance. Failure to observe these precautions could result in serious bodily injury, damage to the equipment, voiding of the warranty, or operational difficulty. Safety notices are presented in this manual in three forms: c WARNING: Refers to personal safety. Alerts the user to potential danger. Failure to follow warning notices could result in personal injury or death. a CAUTION: Directs the users attention to general precautions that, if not followed, could result in personal injury and/or equipment damage. N OTE: Highlights information critical to the users understanding of the actuators installation and operation.

Limitorque Actuation Systems L120 Series

FCD LMENIM1201-01 07/06

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Limitorque name Point of Manufacture Unit Size Order Number Serial Number Customer Tagging CE Stamp

Product Capabilities and Features

L120 Series actuators operate without modification in any rising or non-rising stem application for linear action valves. The actuators meet rigid safety requirements. The actuators are available in weatherproof, explosionproof, and submersible configurations. The actuators are compatible with a wide range of control options from stand-alone units with local pushbutton to open standards-based DDC-100 networks with up to 250 actuators. The actuators are designed with integral control packages including plug-in interconnect boards that increase control functionality for stand-alone or networked units. Durable torque overload is provided in both directions of travel.

2.1 Initial Inspection and Storage Instructions

c WARNING: Read this Installation and Maintenance Manual carefully and completely before attempting to store the actuator. Be aware of the electrical hazards.

2.2 Product Identification

The actuator unit nameplate is located on the back of the unit, opposite the limit switch compartment. The nameplate contains the following information:

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Limitorque Actuation Systems L120 Series

FCD LMENIM1201-01 07/06

The motor nameplate is located on the motor. The nameplate contains the following information: ID Number Start Torque Run Torque Enclosure Type RPM Volts Full Load Amps Locked Rotor Amps Insulation Class Duty Horsepower Service Factor Phase Cycles Motor Code Ambient Temperature Connection Diagram Figure 2.1 L120-10 through 40

Handwheel

Motor Actuator Nameplate (hidden) Declutch Lever

Limit Switch/ Controls Compartment

Housing

Limitorque Actuation Systems L120 Series

FCD LMENIM1201-01 07/06

2.3 Inspection and Recording

Upon receipt of the actuator, inspect the condition of the equipment and record nameplate information as follows: 1. Carefully remove actuator from shipping carton or skid. Thoroughly examine the equipment for any physical damage that may have occurred during shipment. If damaged, immediately report the damage to the transport company. 2. Record the actuator nameplate information for future reference; i.e. ordering parts, obtaining further information.

2.4 Storage Procedures

NOTE: The following are our recommended storage procedures to retain maximum product integrity during short-term storage. Failure to comply with recommended procedures will void the warranty. For longer-term storage, contact Limitorque for procedures and recommendations.

2.4.1 Short-Term Storage (less than 1 year)

Actuators are not weatherproof until properly installed on the valve or prepared for storage. Store actuators in a clean, dry, protected warehouse away from excessive vibration and rapid temperature changes. If the actuators must be stored outside, they must be stored off the ground, high enough to prevent them from being immersed in water or buried by snow. 1. Position the actuator in storage with motor and switch compartment horizontal. 2. Connect the internal heaters (if supplied) or place desiccant in the switch compartment. 3. Replace all plastic caps or plugs with pipe plugs and ensure that all covers are tight. 4. If the actuator is mounted on a valve and the stem protrudes from the unit, a suitable stem cover must be provided.

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Limitorque Actuation Systems L120 Series

FCD LMENIM1201-01 07/06

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Actuator Weights
The approximate L120 actuator weights are provided below: Table 3.1 Actuator weights
Actuator Control Types Size NCU L120-10 BIC CLAMSHELL NCU L120-20 BIC CLAMSHELL NCU L120-40 BIC CLAMSHELL Drive 1 Weight (lb./kg) Top HW lb. 100 115 140 140 155 180 190 205 230 kg 45 52 64 64 70 82 86 93 105 Side HW lb. 112 127 152 158 173 198 216 231 256 kg 51 58 69 72 78 90 98 105 116 lb. 107 122 147 153 168 193 212 227 252 Drive 2 Weight (lb./kg) Top HW kg 49 55 67 69 76 88 96 103 114 Side HW lb. 119 134 159 171 186 211 238 253 278 kg 54 61 72 78 84 96 108 115 126

Limitorque Actuation Systems L120 Series

FCD LMENIM1201-01 07/06

Installation Instructions

4.1 Safety Precautions

c WARNING: Read this Installation and Maintenance Manual carefully and completely before attempting to install, operate, or troubleshoot the Limitorque L120 actuator. c WARNING: Be aware of electrical hazards. Turn off incoming power before working on the actuator and before opening the switch compartment. c WARNING: Potential HIGH-PRESSURE vessel Be aware of high-pressure hazards associated with the attached valve or other actuated device when installing or performing maintenance on your L120 actuator. Do not remove the actuator mounting bolts when the actuator is mounted on a rising stem valve unless the valve is in the FULLY OPEN position and there is NO pressure in the line. c WARNING: Do not manually operate the actuator with devices other than installed Handwheel and Declutch Lever. Using force beyond the ratings of the unit and/or using additive force devices such as cheater bars, wheel wrenches, pipe wrenches, or other devices on the actuator Handwheel or Declutch Lever may cause serious personal injury and/or damage to the actuator or valve. c WARNING: Do not work on the actuator while it is mounted on a torque-seated valve.

4.2 Safety Practices

The following checks should be performed to maintain safe operation of the L120 actuator. Mount motors on a horizontal plane, if possible. Keep the switch compartment clean and dry. Keep the valve stem clean and lubricated. Set up periodic operating schedule for infrequently used valves.

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Limitorque Actuation Systems L120 Series

FCD LMENIM1201-01 07/06

Carefully check for correct motor rotation direction. If the motor is driving the valve in the wrong direction, interchange any two leads on three-phase motors or switch the armature leads on DC and single-phase motors. Use a protective stem cover. Check valve stem travel and clearance before mounting covers on rising stem valves. Verify all actuator wiring is in accordance with the applicable wiring diagram, national and local codes, and Table 4.1. Table 4.1 Required Rating for External Wiring
Up to: 40C 60C Use wire rated at least: 60C 75C

4.3 Initial Actuator Preparation

Replace all molded plastic conduit and top protectors (installed for shipping purposes only) with pipe plugs when installation wiring is complete.

4.3.1 Mounting Base

The mounting hole sizes and quantities are as detailed in Table 4.2. Table 4.2 Mounting Base Dimensions
Actuator Size L120-10 L120-20 L120-40 Mounting Holes Quantity 4 4 4
3 5 5

Tap size MSS 8-16x0.88 8-11x1.25 8-11x1.25 ISO M10x1.5x22.4 M16x2x32 M16x2x32

4.3.2 Stem Acceptance

The maximum stem acceptance is provided in Table 4.3. Table 4.3 Maximum Stem Acceptance
Drive 2 Actuator size inch L120-10 L120-20 L120-40 1.25 2.25 2.625 Tapped mm 32 57 66 inch 1.00 1.875 2.125 Bore mm 25 47 52 inch 1/4x3/32 1/2x3/16 1/2x3/16 Drive 1 Key mm 8x6 14x9 16x10

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Limitorque Actuation Systems L120 Series

FCD LMENIM1201-01 07/06

4.4 Torque Switch

The torque switch is designed to protect the actuator in open and close directions. a CAUTION: Disconnect all incoming power before opening limit switch compartment or working on the torque switch. Do not use abrasive cloth to clean the contacts on the torque switch. Do not torque seat 90 operation valves nor run them against the stops. This may cause damage to the valve. NOTE: If the actuator has torqued out, release torque buildup by operating the actuator manually.

4.4.1 Setting Torque Switch

The torque switch was set at the factory according to customer-supplied information regarding necessary torque or thrust output that was provided at the time of the order. However, if the setting needs to be adjusted, perform the following procedure: a CAUTION: A torque switch limiter plate is provided on most actuators. Removal or modification of the torque switch limiter plate will void the actuator warranty. Do not exceed the setting indicated by this plate without contacting the Limitorque service department. Installing or adjusting the torque switch with the actuator in a loaded condition will result in a loss of torque protection. Item letters correspond to Figure 4.1. 1. Place the L120 actuator in manual mode. 2. Release the load on the wormshaft spring pack. 3. For open and close directions, loosen Screw (A) and move Pointer (B) to desired position. A higher number indicates a high torque and/or thrust output. 4. Tighten Screw (A). 5. Operate the valve electrically to seat valve and to ensure tight shutoff. 6. Rebalance torque switch if required. Figure 4.1 Microswitch-Style Torque Switch and 600 Volt Torque Switch
B A Maximum Stop Setting Plate
OP EN

B Maximum Stop Setting Plate

-20

-10

-10

-20

Balancing Screws
OS E

Balancing Screws

CL

Index Marks

Mounting Screw

Index Marks A B

Mounting Screw

11

Microswitch-Style Torque Switch

600 Volt Torque Switch

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Limitorque Actuation Systems L120 Series

FCD LMENIM1201-01 07/06

4.4.2 Balancing Torque Switch

Item letters correspond to Figure 4.1. 1. Place the actuator in manual mode. 2. Remove the load from the wormshaft spring pack. 3. Note the open and close torque switch settings prior to reinstalling the torque switch. 4. Loosen Screws (A) and position both Pointers (B) at the #1 setting, tighten Screw (A). In this position the index marks should be aligned. 5. Loosen balancing screws and install the torque switch. The base of the torque switch should be flush against the compartment and the hole for the mounting screw should be aligned. 6. Install the mounting screw. 7. Tighten the balancing screws. a CAUTION: The balancing screws should not be touched except during the balancing procedure. The switch is now balanced and ready for the pointers to be returned to their original settings.

4.5 Geared Limit Switch

a CAUTION: The geared limit switch is not preset at the factory and must be adjusted after the actuator has been mounted on associated equipment. Disconnect all incoming power to the actuator prior to opening the limit switch compartment and adjusting the switch. Consult the relevant wiring diagram for limit switch contact development. All L120 units are supplied with 16-contact limit switches - four switches on each of the four rotors. Two rotors are used for end of travel indication. The remaining two rotors may be adjusted for any intermediate point of travel. Do not use abrasive cloth to clean the contacts on the limit switch. Do not attempt to repair gearing in the limit switch. Replace entire gear frame assembly if necessary.

4.5.1 Setting Limit Switch

Set the limit switch as follows. All item letters and piece numbers refer to Figure 4.2. NOTE: See chart below for maximum number of drive sleeve turns for each unit size. The Intermediate Shaft (B), shown in Figure 4.2, may take a considerable number of turns before rotor trip occurs. Table 4.4 Maximum Number of Drive Sleeve Turns for Standard Four-Gear and Optional Five-Gear Limit Switches
Actuator Size Four-Gear 630 740 640 Five-Gear 6300 7400 6400

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L120-10 L120-20 L120-40

Limitorque Actuation Systems L120 Series

FCD LMENIM1201-01 07/06

c WARNING: Potential Explosion Hazard. Do not use a variable speed electric drill for setting the limit switch in an explosive environment. a CAUTION: When setting the limit switch rotor segments (cams) using a variable speed electric drill, do not run drill at speeds higher than 200 RPM. Operating the drill at high speeds can damage the gearing within the limit switch. Figure 4.2 Limit Switch
7 8 6 Piece 5 B A 9 3 2 4 1 2 3 4 5 6 7 8 9 Quantity 1 2 12 4 4 4 4 8 4 Description Gear Frame Assembly Eight-Switch Contact Block Assy. Rotor Segment (short) Rotor Shaft Machine Screw Flat Washer Lock Washer Hex Nut Rotor Segments (long)

4.5.2 Setting Procedure (Refer to Figure 4.2)

1. Open the Compartment Cover (piece #200 of Figure 5.2). 2. Put the actuator into manual operation. Use the handwheel to operate the valve in the open direction. While operating the valve, note the direction of the Intermediate Shaft (B) corresponding to the rotor or rotors to be set. 3. When the valve is fully open, close it one turn of the handwheel to allow for coast of moving parts or refer to the valve manufacturer setting requirements. 4. Push in the Setting Rod (A) and turn one-quarter turn. The rod will latch in this depressed position. 5. Refer to the applicable wiring diagram for contact development. The limit switch contact is closed when the rotor is engaged with the plunger. If the rotor to be set has not turned 90 degrees to operate the plunger, turn the intermediate shaft in the same direction as noted in Step 2 until the rotor clearly trips the switches. This rotor is now set correctly. 6. Before moving the valve, depress and turn the Setting Rod (A) one-quarter turn to the spring released position. Insert a screwdriver into the intermediate shafts to ensure that they will not move. a CAUTION: Do not operate the valve when Setting Rod (A) is in a fully depressed position. Loss of contact setting will occur and the setting rod will be damaged. 7. Operate the valve by handwheel to fully close position; reverse direction by one turn of the handwheel to allow for coast of moving parts or refer to the valve manufacturer setting requirements. 8. Set the other rotors by following Steps 4 through 6.

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Limitorque Actuation Systems L120 Series

FCD LMENIM1201-01 07/06

Figure 4.3 Setting the open and closed contacts

Closed position

Open position

4.5.3 Combination of Contacts (Refer to Figure 4.2)

The rotor segments can be separated and rotated through 90 degrees to give various combinations of normally open or normally closed contacts to each rotor. 1. Remove Nuts (piece 8) and Fillister Head Machine Screws (piece 5, for a total of two fasteners on each side of the switch). 2. Remove complete contact assembly from the back plate. 3. Rearrange cams on the camshaft to produce the required combination of contacts. 4. Replace contact assembly on back-plate (ensuring that the registers fit correctly) and secure with the machine screw and nuts. 5. Set limits according to the procedure above.

4.6 Position Indication

4.6.1 Local position indication
The local dial position indicator is factory-selected to show valve position. The position indicator can only be adjusted when mounted on the valve. To set the local position indicator: 1. Disconnect all incoming power and remove Switch Compartment Cover (piece 200 of Figure 5.2). 2. Place the valve in the fully close position.

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3. Loosen the round head machine screw which holds the pointer in place, move the pointer to the O position, and retighten the screw. The indicator is now set.

Limitorque Actuation Systems L120 Series

FCD LMENIM1201-01 07/06

NOTE: The end-of-travel rotors of the geared limit switch activate Flip-flop type indicators. This type of indicator will require no further setting after the geared limit switch has been adjusted.

4.6.2 Remote Position Indication

The L120 actuator with a position transmitter installed, transmits a 4-20 mA output signal to a remote position indicator. The transmitter responds to input of a 1K (ohms) potentiometer and can be powered by 18 VAC or 24 VDC. NOTE: The pinion has been left disengaged to prevent damaging of rheostat prior to setting the valve. Set rheostat by turning pinion until the desired reading is obtained. Loosen the hex nut on the back of the rheostat and slide the rheostat in the direction of the idler pinion until pinions are engaged. Do not force engagement of the pinions. Retighten hex nut on back of the rheostat. Do not engage pinion until unit and valve have been set. To Calibrate Position Transmitter 1. Position the actuator to mid-travel: valve at 50% position. 2. Disconnect the potentiometer wiring harness from the transmitter board and measure the resistance from each end connection to the center connection on the potentiometer. 3. Set the potentiometer to the correct resistance reading. Loosen the set screw that retains the spur gear on the potentiometer shaft and rotate the shaft until a reading of 500 ohms is achieved. 4. Tighten the set screw and reconnect the wiring harness. 5. Run the actuator fully CLOSED. 6. Calibrate ZERO position by adjusting the zero potentiometer until a 4 mA output signal is read at terminal +VE and -VE. 7. Run the actuator fully OPEN. 8. Calibrate SPAN position by adjusting the span potentiometer until a 20 mA output signal is read at terminals +VE and -VE. 9. Repeat steps 5 to 8 and fine-tune as necessary. Figure 4.4 1000 ohm Potentiometer
1000 ohms Gearing Receiver + DC Power Supply + Customer Equipment Typical Connection for a 1000 ohm Potentiometer

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Limitorque Actuation Systems L120 Series

FCD LMENIM1201-01 07/06

4.7 Optional Side-Mounted Handwheel

For actuator sizes L120-10, 20, and 40, the handwheel can be mounted on the side as shown in the following figures. Figure 4.5 L120-10 parts list, attachment ratio 4.2:1
182-2 182-1 182-3 178 & 179 181 180 177

157-4 157-3 & 157-6

154

Piece 6 42-11 44 45 150 151 152 153

Quantity 1 1 1 1 1 1 1 1 1 4 4 2 1 2 2 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1

Description Housing Cover Shim O-Ring / Handwheel Mounting Quad Ring Pipe Plug Bevel Housing Bevel Housing Adapter Bearing Cap Bevel Gear Bevel Pinion Shaft Hex Head Cap Screw Lockwasher Socket Head Cap Screw Roll Pin Socket Head Cap Screw Lockwasher Quad Ring O-Ring O-Ring Quad-Ring Ball Bearing Seal Insert Spacer Retaining Ring Grease Fitting Handwheel Hex Head Cap Screw Lockwasher Key Retaining Washer Handwheel Spinner Socket Head Cap Screw Hex Jam Nut

157-5

154 157-1 157-2 157-3 157-4 157-5 157-6 158-1 158-2 158-3 158-4 160 161 164 169 171 177

158-1 158-3 160 171

161

169 152 164 158-4 Note: Apply Loctite 601/609 to ID of Bearing Cap

178 179 180 181 182-1 182-2 182-3

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45 157-1 150 & 157-2 158-2 151 153 6

44 42-11

Limitorque Actuation Systems L120 Series

FCD LMENIM1201-01 07/06

Figure 4.6 L120-20 with side-mounted handwheel and parts list, attachment ratio 5.7:1
179 & 178 181 180 177

182-2 182-1 182-3 157-5 157-3 & 157-4 157-1 & 157-2

Piece 6 42-11 44 45 150 151 152 153 154 157-6 157-1 157-2 157-3 157-4 157-5 157-6 158-1 158-2 158-3 158-4 160 161 169 171 177 178 179 180 181 182-1 182-2 182-3

Quantity 1 1 1 1 1 1 1 1 1 4 4 4 4 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Description Housing Cover Shim O-Ring / Handwheel Mounting Quad Ring Pipe Plug Bevel Housing Bevel Housing Adapter Bearing Cap Bevel Gear Bevel Pinion Shaft Hex Head Cap Screw Lockwasher Hex Head Cap Screw Lockwasher Roll Pin Socket Head Cap Screw Quad-Ring O-Ring O-Ring Quad Ring Ball Bearing Seal Insert Retaining Ring Grease Fitting Handwheel Hex Head Cap Screw Lockwasher Key Retaining Washer Handwheel Spinner Socket Head Cap Screw Hex Jam Nut

158-1 154 158-3 171

161 152 169 160

Note: Apply Loctite 601/609 to ID of Bearing Cap 158-2 158-4

45 153 150 151 44 6 42-11

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Limitorque Actuation Systems L120 Series

FCD LMENIM1201-01 07/06

Figure 4.7 L120-40 with side-mounted handwheel and parts list, attachment ratio 12:1
182-2 182-1 182-3 179 & 178 181 180 177 Piece 6 42-11 158-1 Note: Apply Loctite 601/609 to ID of 164 Bearing Cap 155 163 157-7 161 160 169 167 157-3 & 157-4 159 164 44 45 150 151 152 153 154 155 156 157-1 157-2 157-3 157-4 157-5 Section Through Pinion 157-6 157-7 158-1 158-2 158-3 158-4 Handwheel 157-6 171 158-5 158-4 154 152 158-3 151 158-5 159 160 161 163 164 167 169 171 45 177 178 179 157-1 & 157-2 150 157-5 158-2 153 171 156 6 44 42-11 180 181 182-1 182-2 182-3 Quantity 1 1 1 1 1 1 1 1 1 1 1 4 4 4 4 8 2 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 Description Housing Cover Shim O-ring / Handwheel Mounting Quad Ring Pipe Plug Bevel Housing Cover Bevel Housing Spur Gear Cover Bevel Gear Bevel Pinion Input Pinion Shaft Bevel Gear Adapter Hex Head Cap Screw Lockwasher Hex Head Cap Screw Lockwasher Socket Head Cap Screw Dowel Pin Socket Head Cap Screw Quad Ring O-ring Gasket Quad Ring O-ring Spur Gear Ball Bearing Seal Insert Ball Bearing Ball Bearing Key Retaining Ring Grease Fitting Handwheel Hex Head Cap Screw Lockwasher Key Retaining Washer Handwheel Spinner Socket Head Cap Screw Hex Jam Nut

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Limitorque Actuation Systems L120 Series

FCD LMENIM1201-01 07/06

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6. Check output rotation:

Operation

c WARNING: Do not manually operate the actuator with devices other than installed Handwheel and Declutch Lever. Using force beyond the ratings of the unit and/or using additive force devices such as cheater bars, wheel wrenches, pipe wrenches or other devices on the actuator Handwheel or Declutch Lever may cause serious personal injury and/or damage to the actuator or valve. a CAUTION: Do not motor-operate the valve without first setting or checking the limit switch setting and motor direction. Do not force the declutch lever into hand operation. If the clutch does not easily engage, rotate handwheel slowly while operating the declutch lever. Do not alternately start/stop the motor to open or close a valve which is too tight for normal operation.

5.1 Electrical Start-up

1. Verify that the actuator has been correctly lubricated. This is particularly important if the actuator has been in long-term storage. 2. Verify that the geared limit switch has been correctly set (see Section 4.5.1, Setting Limit Switch). 3. If the valve stem is not visible, remove the stem cover or handwheel cover plate to observe output direction of the drive sleeve. 4. Engage manual operation and hand crank the valve well away from end of travel positions. 5. Turn on power supply and push button to open.

If phase rotation is correct, the valve should begin to open. If valve begins to CLOSE, STOP immediately. Incorrect phase rotation will lead to serious damage if the valve seats.

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Limitorque Actuation Systems L120 Series

FCD LMENIM1201-01 07/06

7. Correct the phase rotation one of two ways: Switch any two of the three power leads for three-phase power, or Reverse the armature leads for single-phase or DC power. The actuator should operate correctly and will be stopped at the end of travel positions by torque or limit switch functions. Table 5.1 Required Rating for External Wiring
Up to 40C 60C Use wire rated at least 60C 75C

Figure 5.1 is a representation of a typical application and may not be applicable to your specific actuator. Please refer to the wiring diagram supplied with your actuator to confirm the actual equipment supplied.

5.2 Manual Operation

Piece numbers refer to Figure 5.2. Counterclockwise rotation of the Declutch Lever (piece 9) causes the declutch actuator to lift the clutch sleeve out of engagement with the worm gear. Drive lugs on top of the clutch sleeve engage matching lugs in the Handwheel Adapter (piece 26) and then latches engage the clutch sleeve in this position. The actuator is now in the handwheel driving option. Energizing the motor at this point will cause the latches to drop out and the spring-loaded clutch sleeve reengages with the lugs on the worm gear. The actuator is once more in motor operation. NOTE 1: The shift from manual operation to motor operation is automatic and does not require external positioning of the declutch shaft. NOTE 2: If the declutch mechanism does not engage, rotate handwheel approximately 30-45 and attempt manual engagement. There is a chance that the lugs on the Clutch Sleeve (piece 19) and Handwheel Adapter (piece 26) are not correctly aligned.

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Limitorque Actuation Systems L120 Series

FCD LMENIM1201-01 07/06

Figure 5.1 (one of two) L120-10 through 40 typical wiring diagram

GND L1 L2 L3 10 13 12 11 FUSE FUSE O O O C E CPT BLU RED WHITE BLU YEL YEL 115 V 18 V 18 V C C GREEN/WHITE GREEN/WHITE T1 T2 T3

MOTOR

A B E D E BLACK

ALTERNATE TRANSFORMER TYPES 1 2 3 500 600 230 V 480 575 H1 AND H3 TO L1 460 550 H2 AND H4 415 TO L2 380 -

TAPS

WHITE

BLACK (7)

7 (7C) 3

RED

RES

R WHITE

BLACK BLACK BLACK (3) (3C)

GREEN ELEC HTR 21/22 H1 MTR HTR

RES

G WHITE H2 19/20 GREEN/WHITE P2 5 (5) (5C) 18 BLUE BLACK C BLUE WHITE O P1 TH.OL P1

PB1 OPEN BLUE SS OFF LOCAL REMOTE BLACK PB2 STOP BROWN RED PB3 CLOSE RED YELLOW (8) BLUE BROWN PURPLE O YELLOW C BROWN ORANGE GRAY PINK 2 3 4 5 6 1 BLUE

4 BLUE (4) (4C) RED

(18) (18C)

JUMPER SEE NOTE #5 8 (8C) OPEN (1) CLOSE STOP BROWN BLACK COMMO N REMOTE IND REMOTE IND YELLOW RED 17 (17) (17C) 1 (1C) POT (OPTIONAL )

YELLOW BLACK

YELLOW WHITE

P1

16

17

GRAY

Valve shown in full open position

CONTACT LIMIT SWITCH CONTACT DEVELOPMENT VALVE POSITION FULLY A B OPEN 17 FULLY CLOSED FUNCTION BYPASS CIR SPARE IND LIGHT OPEN LIMIT BY-PASS CIR SPARE IND LIGHT CLOSE LIMIT SPARE SPARE SPARE SPARE SPARE SPARE SPARE SPARE 18 CLOSING TORQUE SWITCH INTERRUPTS CONTROL CIRCUITIF MECHANICAL OVERLOAD OCCURS DURING CLOSING CYCLE OPENING TORQUE SWITCH INTERRUPTS CONTROL CIRCUIT IF MECHANICAL OVERLOAD OCCURS DURING OPENING CYCLE Legend O-OPEN CONTACT C-CLOSE CONTACT O OPENING COI L C CLOSING COIL CPT-CONTROL POWER TRANSFORMER +-MECHANICAL INTERLOCK TH.OL-THERMAL OVERLOAD CONTACTS R RED INDICATING LIGHT G GREEN INDICATING LIGHT SS-SELECTOR SWITCH (LOCAL-OFF-REMOTE ) PB1-OPEN PUSHBUTTON PB2-STOP PUSHBUTTON PB3-CLOSE PUSHBUTTON ELEC HTR-COMPARTMENT HEATER MTR HTR-MOTOR HEATER POT-POTENTIOMETER (OPTIONAL, SEE CERTIFICATION SHEET IF SUPPLIED) RES-LAMP RESISTORS

ROTOR

OPEN

CLOSE

INT.1

INT.2

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Notes OPEN CONTACT 1. CLOSE CONTACT 2. 3. SEE CERTIFICATION SHEET FOR VOLTAGE SUPPLIED. TRANSFORMER UNUSED WIRES TO BE SEPARATEL Y COVERED WITH INSULATING HEAT SHRINK TUBING. 4. ROTORS INT.1 & INT.2 CAN BE SET AT VALVE POSITION FULL OPEN, FULL CLOSED OR ANY POSITION IN BETWEEN AS INDICATED BY POINTS A AND B. 5. ADD JUMPER ON LS#8 BETWEEN TERMINALS (8 ) & (8C) FOR TORQUE-SEATING VALVES.

RED 18

RED

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Limitorque Actuation Systems L120 Series

FCD LMENIM1201-01 07/06

Figure 5.1 (two of two) L120-10 through 40 typical wiring diagram

MOTOR
REVERSING STARTER
L1F L2F P1 P1 T1 T2 T3 T1 T2
T1 T2 T3 P1
MTR HTR

TH.OL

GRN/WHT

L1

L2

L3

L3

L2

WHT BLK

WHT BLK

ELEC HTR

BLK

L1

PRIMARY SECONDAR Y

(NOTE#3)

T3

CPT

YEL/WHT BLU/WHT

H1 H2 PUR P2

115 V 75 VA

18 V 10 VA

BLU

BLU BLK

YEL BLK

BLK

RED

YEL

FUSE

1 YEL

BLU

BLU

YEL

WHT

18 V 10 VA

PUR

MOTOR GROUND LUG

SW323 PUSHBUTTON STATION

1

BLU BLU BLK/WHT RED/WHT

(18C)

OPEN 18

FOR SIGNAL CONVERTER USE WHEN SUPPLIED

2 1 2

BLU/RED BLU/BLK YEL/RED YEL/BLK

RED WHT

R PB1 OPEN

WHT

G PB3 CLOSE

GRN

TORQUE SWITCH

(18)

CLOSE
(17C)

PB2 STOP

17

(17)

BLK BLU

RED BRN YEL

LIMIT SWITCHES
(13C)
(9C)

LIMIT SWITCHES
BLU/BLK BLU/RED
(5C) (1C)

LOCAL
YEL/BLK YEL/RED
BRN

OFF

REMOTE
ORG

13
(13) (14C)

9
(9)

5
(5) (6C)

1
(1) (2C)

RED PUR BRN

(10C)

14
(14) (15C)

10
(10)

6
(6)

2
(2) (3C)

(11C)

RED BLK YEL/RED YEL

(7C)

GRN BLK BLU/RED

RES RES

GRY

PNK

15
(15) (16C)

11
(11) (12C)

7
(7) (8C)

3
(3) (4C)

16
(16)

12
(12)

8
(8)

4
(4)

BLUE

INT.2 ROTOR

INT.1 ROTOR

CLOSE ROTOR

OPEN ROTOR
1 2

GRN RED WHT BLK BLU PUR YEL

POT (OPTIONAL)

LIGHTS
1 2

BLK

BRN

RED

3 4

BUTTONS
1

BRN GRY PNK ORG

REMOTE OPEN REMOTE CLOSE REMOTE STOP REMOTE COMMON SELECTOR SWITCH IN REMOTE INDICATION FOR SIGNAL CONVERTER USE (WHEN SUPPLIED) SPARE INCOMING POWER GROUND L3 INCOMING POWER L2 INCOMING POWER L1 INCOMING POWER

1 2 3 4 5 6 7 8 9 10 11 12 13

BLU YEL BRN ORG GRY PNK BLK/WHT RED/WHT BLK BRN RED GRN/WHT WHT WHT BLK BLK GRN/WHT L3 L2 L1

14 15 16 17 18 19 20 21 22

SPARE SPARE POT (CCW) POT (SWEEPER) POT (CW)

P2 H2 H1

2 3 4

AUX. TERM.

WIRE COLOR LEGEND

: BLU BLUE : YEL YELLOW : PUR PURPLE : BLK BLACK : ORG ORANGE : BRN BROWN : WHT WHITE : RED RED : GRN GREEN : PNK PINK : GRY GRAY COLOR/STRIPED

L2 L1

CHASSIS GROUND

L2F L1F
FUSES

Electrical Compartment

22

Limitorque Actuation Systems L120 Series

FCD LMENIM1201-01 07/06

Figure 5.2 (one of two) L120-10 through 40 drive sleeve and housing cover parts breakdown

29 50

26 44 43 27

Piece 16 17 18 19 20 21 22 23 24 25 26 27 28 29 33 34 42/11 43 44 50

Quantity 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1* 1* 1 1 1 A/R

Description Ball Bearing Ball Bearing Drive Sleeve Bevel Gear Handwheel Clutch Sleeve Worm Gear Lug Ring Worm Gear Spirolox Retainer Key Declutch Spring Drive Sleeve Handwheel Adapter Piece Housing Cover Retaining Ring Handwheel Handwheel Cover Plate Handwheel Cover Plate Gasket O-ring / Handwheel Mounting Quad Ring Quad Ring Hardware Quantity Description

28 42/11 17 18

24 19

25

20 21 22 16

23

* Not shown

2

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Limitorque Actuation Systems L120 Series

FCD LMENIM1201-01 07/06

Figure 5.2 (two of two) L120-10 through 40 parts breakdown

50 312 31 39 42/7* 38 40 2 50 30 19 21 46 1 50 42/3 11 42/6 42/5 7 9 37 305 300 47 50 3 4 42/9 36 15 35 9 25 10 5 310 50 50 50 42/11

200

50

Piece 1 2 3 4 5 6 7 9 10 11 15 19 21 25 30 31 32 35 36 37

Quantity 1 1 1 1 1 1** 1 1 1 1 1 1 1 1 1 1 4** 1 1 1

Description Housing Motor Adapter Electrical Compartment Seal Retainer Worm Shaft End Cap HSG. Cover Shim Set Declutch Shaft Assembly Declutch Lever Roll Pin Declutch Cap Worm Shaft Assembly Clutch Sleeve Worm Gear Drive Sleeve Nipple Flange Motor Dowels Worm Shaft Gear Key Flexloc Nut

Piece 38 39 40 41 42 42/3 42/5 42/6 42/7 42/7* 42/9 42/11 46 47 50 200 300 305 310 312

Quantity Description 1 1 1 1** 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Motor Pinion Key Stop Nut Washer Seals Kit Gasket Mtr Adapter O-ring Declutch Assembly O-ring Declutch Lever O-ring Mtr Gasket Mtr Seal Drive Sleeve O-Ring Handwheel Mounting O-ring / Motor Nipple O-ring / Cover Hardware Kit Compartment Cover Torque Switch Geared Limit Switch Unit Nameplate Rimpull Nameplate

* L120-40 Only

2

** Not Shown

Limitorque Actuation Systems L120 Series

FCD LMENIM1201-01 07/06

5.3 Motor Operation

The actuator is always available for motor operation whenever the motor is energized a CAUTION: Do not force the declutch lever into motor operation. Lever will automatically return to motor operation when the motor is energized. Reset the travel limit switches prior to motor operation if the actuator has been dismantled or removed from the valve. Piece numbers refer to Figure 5.2. In motor operation, the Motor Gear Set (piece 35 and 38) drives the Wormshaft (piece 15) and Worm Gear (piece 21) which in turn rotates the Clutch Sleeve (piece 19) by means of driving the lugs. The clutch sleeve and worm gear may be assembled to produce either a no lost motion or hammerblow effect. The Drive Sleeve (piece 25) is keyed to the clutch sleeve and hence rotates, producing the required output rotary motion.

5.4 Torque and Travel Limiting

The geared limit switch is driven by a bevel gear connected to the upper drive lugs of the clutch sleeve. The limit switch is directly connected to the output of the actuator. Once properly set, the limit switch remains in step with the valve position regardless of electric or manual operation of the Limitorque actuator. The worm and wormshaft are supported by two rotating spring packs. As torque is generated by the actuator, the worm moves axially against one of the spring packs. Each pack is precalibrated and hence a finite compression represents a finite torque output. Movement of the worm operates the torque switch, which interrupts the power to the motor. The torque switch is adjustable and can be set to operate at predetermined torque levels.

2

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Limitorque Actuation Systems L120 Series

FCD LMENIM1201-01 07/06

6
26

Maintenance
6.1 Lubrication
The L120 series actuators have a totally sealed gear case, factory-lubricated with grease. The thrust base, when supplied, is factory-lubricated with the same grease as the gear case if the stem nut is factory-machined for the customer's driven shaft. If a blank stem nut is installed in the thrust base, a tag is provided on the actuator advising that the base is not lubricated. The gear case can be mounted in any position. However, mounting of the motor or the switch compartment in the down position is not recommended. These mounting positions may result in the motor or switch compartment being saturated with lubricant if the seal fails. No seal can remain absolutely tight at all times. Therefore, it is not unusual to find a very small amount of weeping around shaft sealsespecially during long periods of idleness such as storage. Using grease minimizes this condition as much as possible. If a small amount is weeping at start-up, remove it with a clean cloth. Once the equipment is operating on a regular basis, the weeping should stop.

6.1.1 Lubrication Inspection

Inspect Limitorque L120 series actuators for correct lubrication prior to operating - particularly following a long storage period. Each application has its own effect on the actuator and the frequency of these inspections should be based on the application and the operating experience. The following lubrication inspection schedule is recommended until operating experience indicates otherwise. For Gear Case, inspect lubrication every 18 months or 500 cycles, whichever occurs first. During an inspection consider the following: Quantity Ensure there is enough lubricant so that the Worm and the Worm Gear are totally immersed in grease regardless of the position. To verify, pull out geared limit switch. Level of grease should be within 1/2" from bottom of geared limit switch opening.

Limitorque Actuation Systems L120 Series

FCD LMENIM1201-01 07/06

Quality Inspect lubricant for dirt, water or other foreign matter. If any one of these is found: 1. Flush the actuator with a commercial degreaser/cleaner such as Exxon Varsol #18. This degreaser/cleaner is not corrosive and does not affect the seal materials. 2. Repack the actuator with fresh lubricant allowing room for grease thermal expansion. Consistency Ensure the lubricant is fluid approximating a standard NLGI-0 grade consistency or less. Thinners such as Amoco WAYTAC #31 oil may be added provided the volume of thinner does not exceed 20% of the total lubricant.

6.1.2 Factory Lubricant

Gear Case: The L120 series actuator gear case is factory-lubricated with an EP-0 lithium grease, suitable for temperatures from -20F (-29C) to +250F (+121C). Table 6.1 Specified Approximate Lubricant Weights
Actuator Size L120-10 L120-20 L120-40 lb. 2.75 4.25 5.75 kg 1.3 1.9 2.6

Geared Limit Switch: Permanently lubricated with Beacon 325. Limitorque does not recommend disassembly of the gearbox.

6.2 Minimum Lubricant Qualities Required

The standard lubricants used by Limitorque have been proven to be extremely reliable over years of service. Limitorque does not recommend a particular lubricant substitute for the standard lubricants; however, Limitorque does require the following lubricant qualities as a minimum. a CAUTION: Do not mix lubricants of a different base chemical. Mixing lubricant bases may cause lubricant properties to be ineffective. The Lubricant must: contain an EP additive. be suitable for the temperature range intended. be water and heat-resistant and non-separating. not create more than 8% swell in Buna N or Viton. not contain any grit, abrasive, or fillers. comply with a slump-prefer NLGI-0 grade. not be corrosive to steel gears, ball, or roller bearings. have a dropping point above 316F (158C) for temperature ranges of -20F (-29C) to +250F (+121C).

27

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Limitorque Actuation Systems L120 Series

FCD LMENIM1201-01 07/06

6.3 Disassembly and Reassembly

a CAUTION: Turn off all power services before attempting to perform service on the actuator. Remove the actuator from the valve for complex work. Minor work, such as replacing geared limit switch, torque switch, or motor, may be readily performed while the actuator is still on the valve. Potential High-Pressure Vessel. Before removing or disassembling your actuator, ensure that the valve or other actuated device is isolated and is not under pressure. NOTE: If the actuator is fitted with a Thrust Base (piece 100 of Figure 6.2), it is possible to remove the actuator housing while leaving the base on the valve to accept valve thrust. However, it is preferred that the valve be isolated from service and, if it is a rising stem, that the valve be fully open.

6.4 Disassembly of the L120-10, 20, and 40

Unless otherwise noted, piece numbers refer to the Illustrated Parts Breakdown of Figure 5.2. 1. Turn off power to the actuator. 2. Remove electrical Compartment Cover (piece 200). 3. Disconnect all electrical leads from the Torque Switch (piece 300) and Geared Limit Switch (piece 305). Ensure that all leads and terminals are clearly marked to facilitate reassembly. 4. Remove two screws holding limit switch and one holding torque switch. Remove both items. 5. Remove four bolts holding Motor (piece 31) and three bolts holding conduit Nipple Flange (piece 30). Remove motor, drawing motor leads through switch compartment. 6. Remove Motor Pinion (piece 38) by removing Stop Nut (piece 40). 7. Remove Worm Shaft Gear (piece 35), Flexloc Nut (piece 37), and Worm Shaft End Cap (piece 5) and draw complete wormshaft assembly from housing. NOTE: The wormshaft has been assembled at the factory to obtain the correct preload on the spring packs. Do not attempt to disassemble further. If the worm shaft is worn or damaged, it is suggested that the complete wormshaft subassembly be replaced. The actuator must be in motor operation to remove the wormshaft assembly. When the wormshaft is partially out, the disc springs will hit the worm gear. Pull the declutch lever forward slightly without fully engaging the declutch mechanism and the wormshaft will come out. 8. Remove Declutch Cap (piece 11). 9. For unit size L120-10, completely withdraw the Declutch Assembly (piece 7 of Figure 6.3) from the housing. For unit sizes L120-20 and 40, remove Declutch Input Pinion (piece 12 of Figure 6.3) followed by the Declutch Assembly (piece 7 of Figure 6.3). 10. Remove Handwheel (piece 29) and Housing Cover (piece 27) and lift complete drive sleeve subassembly from housing.

2

Limitorque Actuation Systems L120 Series

FCD LMENIM1201-01 07/06

6.5 Drive Sleeve and Housing Cover Disassembly

Piece numbers refer to Figure 5.2. 1. Remove Upper Ball Bearing (piece 17), Bevel Gear (piece 18), Declutch Spring (piece 24), Clutch Sleeve (piece 19), and Key (piece 23). 2. Remove Lower Ball Bearing (piece 16). 3. Spirolox Retainer (piece 22) may now be removed by inserting small flat blade screwdriver under the end of the ring and prying the first layer from the groove. Continue around the ring until it is free from the groove. 4. Remove the Worm Gear (piece 21) and the Lug Ring (piece 20). 5. Handwheel Adapter (piece 26) and Seal (piece 42) can be removed from Housing Cover (piece 27) by removing Retaining Ring (piece 28).

6.6 Torque Nut Disassembly (Drive 1 Option)

For applications requiring torque only, the L120 series actuator can be supplied without the thrust base option. The torque nut is driven by the drive sleeve lugs and held in place by the torque bushing connector. Figure 6.1 L120-10 through 40 standard and extended drive sleeve assembly
99 97 25 96 25 Piece 25 95 96 98 97 98 95 99 183 Quantity 1 1 1 1 1 1 1 Description Drive Sleeve Torque Nut Torque Bushing Connector Torque Bushing Washer Retaining Ring Elastic Stop Nut Retaining Ring

95

183 Standard

183

Extended

Unless otherwise stated, piece numbers refer to Figure 6.1. Standard Drive Sleeve To remove the Torque Nut (piece 95), remove Retaining Ring (piece 183) and drop the torque nut out the bottom of the Drive Sleeve (piece 25 of Figure 5.2).

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Limitorque Actuation Systems L120 Series

FCD LMENIM1201-01 07/06

Optional Drive Sleeve 1. Remove the Handwheel (piece 29 of Figure 5.2), Handwheel Cover Plate (piece 33 of Figure 5.2) and Gasket (piece 34) to provide access to the Elastic Stop Nut (piece 99). 2. Remove the Elastic Stop Nut (piece 99) from the Rod (piece 1). The Torque Nut (piece 95) can now be removed from the bottom of the Drive Sleeve (piece 25 of Figure 5.2). 3. The Torque Bushing Connector (piece 96) can be removed from the torque nut by removing the Retaining Ring (piece 98).

6.7 Thrust Base Disassembly (Drive 2 Option)

Piece numbers refer to Figure 6.2. 1. If the Thrust Base (piece 100) option is present, remove the Seal Retainer (piece 102) followed by Stem Nut (piece 101). 2. Remove the four Hex Head Cap Screws (piece 110) and the Lift Thrust Base from the housing. Figure 6.2 L120-10 through 40 thrust base
103 105 104

Piece 107A 109, 112 106 100 105 107 103 104 101 102 108 110, 111 100 101 102 103 104 105 106 107 107A 108 109 110 111 112

Quantity 1 1 1 2 2 2 1 1 1 1 1 4 4 1

Description Base Housing Stem Nut Seal Retainer Needle Bearing Thrust Washer Thrust Washer O-ring Seal Quad Ring Seal Quad Ring Seal Gasket Grease Fitting Hex Head Cap Screw Lock Washer Relief Fitting

NOTE: For the L120-10, use the same part number for piece #107 and 107A. For the L120-20 and L120-40, use two different part numbers for piece #107 and 107A.

6.8 Stem Nut Replacement Thrust Base Applications

This section is only applicable to thrust base applications. Occasionally the operator stem nut may need replacing if used in a threaded stem application on rising stem valves.

0

c WARNING: Possible Hazardous Voltage. Turn power OFF before disassembling or removing the actuator from the mounting base. This will prevent accidental start-up during service to the unit. c WARNING: Potential High-Pressure Vessel. Before removing or disassembling the actuator, ensure that the valve or other actuated device is isolated and not under pressure.

Limitorque Actuation Systems L120 Series

FCD LMENIM1201-01 07/06

a CAUTION: The L120-10 through 40 thrust base contains lubrication. Ensure that EP-00 is replaced when reassembling thrust base. NOTE: Installation and retention of O-rings and quad rings can be eased by applying a small quantity of EP grease to the ring during assembly. To replace the stem nut: 1. Disconnect all incoming power to the actuator. 2. Remove actuator from the valve. 3. Remove Seal Retainer (piece 102 of Figure 6.2) followed by stem nut, bearings, and seals. 4. Check the fit of the new stem nut on the valve stem - ensure that the nut travels freely without binding. 5. Reassemble the thrust base and remount the actuator on the valve. 6. Remount the actuator on the thrust base. 7. Removing the actuator from the valve will change the limit switch settings. Reset the limit switch in accordance with Section 4.5.1, Setting Limit Switch. 8. Reconnect power. 9. Test for correct functioning.

6.9 Reassembly
Piece numbers refer to Figures 5.1, 5.2, 6.1, 6.2, and 6.3. 1. Install Lug Ring (piece 20) onto Drive Sleeve (piece 25) followed by the Worm Gear (piece 21). Ensure that the worm gear lugs engage with recesses on lug ring. 2. Install Spirolox Retainer (separate layers of retainer sufficiently to begin threading the retainer into the drive sleeve groove. Continue threading until the retainer is firmly located in the groove). 3. Install Key (piece 23) and Clutch Sleeve (piece 19). 4. Add the Declutch Spring (piece 24), Bevel Gear (piece 18), Upper Bearing (piece 17), and Lower Bearing (piece 16) to complete the assembly. 5. Replace the drive sleeve assembly into main housing, and secure with the Housing Cover (piece 27). Ensure that all the seals are in place. 6. Insert Wormshaft Assembly (piece 15) into the housing and locate the bearings in the housing journals. Replace the Wormshaft Cap (piece 5). 7. Install the Wormshaft Gear (piece 35) and Flex Loc Nut (piece 37). NOTE: It is recommended that a new flex loc nut be used during reassembly.

1

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Limitorque Actuation Systems L120 Series

FCD LMENIM1201-01 07/06

Figure 6.3 L120-10 through 40 declutch assembly parts breakdown

7 7-1 8 42/5 Declutch Stop 7-2 & 7-3 12 8 42/5 7-1

Declutch Stop

10 7-2 & 7-3 11 7A 42 9 L120-10 11 L120-20/40 10 42 9

Piece 7* 7A Declutch Actuator LUG Handwheel Clutch Sleeve 7-1 8 9 10 11 12* 42/5

Quantity 1 1 1 1 1 1 1 1 1

Description Declutch Shaft Assembly L120-20/40 Declutch Shaft Assembly Declutch Actuator Declutch Latch (left & right) Declutch Return Spring Declutch Lever Roll Pin Declutch Cap Declutch Input Pinion O-ring Declutch

7-2 & 7-3 1

*L120-20/40 only

6.9.1 Declutch Assembly (L120-10)

8. Install Declutch Cap (piece 11) on the Declutch Shaft (piece 7A). Ensure that the return spring is located correctly in the endcap. 9. Replace Declutch Lever (piece 9) on the shaft with the lever against the stop. 10. While holding the cap steady, rotate the declutch shaft against the spring tension until the holes in the shaft and lever align. 11. Replace complete assembly in main housing. Ensure that the lug on the Declutch Actuator (piece 7-1) fits into the groove on the Handwheel Clutch Sleeve (piece 19 of Figure 5.2). 12. Secure the declutch cap. NOTE: When the declutch lever is disengaged against the declutch stop (motor operation position), the Declutch Actuator (piece 7-1) should not be in contact with the groove on the Handwheel Clutch Sleeve (piece 19 of Figure 5.2).

2

6.9.2 Declutch Assembly (L120-20/40) (Refer to Figure 6.3)

8. Install Declutch Cap (piece 11) on the Declutch Pinion Shaft (piece 12). Ensure that the return spring is located correctly in the slots.

Limitorque Actuation Systems L120 Series

FCD LMENIM1201-01 07/06

9. Replace Declutch Lever (piece 9) on the pinion and against the stop. 10. While holding the cap steady, rotate the Pinion Shaft (piece 12) against the spring tension until the holes in the shaft and lever align. 11. Insert Roll Pin (piece 10). 12. Slide Declutch Shaft (piece 7) into the housing, ensuring that the Declutch Shaft (piece 7) fits correctly into the groove in the Handwheel Clutch Sleeve (piece 19 of Figure 5.2). 13. Install the declutch cap assembly into the housing, finding the nearest tooth on the internal spur gear which will allow the cap to be secured without placing tension on the Declutch Actuator (piece 7-1) causing it to rub against the groove in the Handwheel Declutch Sleeve (piece 19 of Figure 5.2).

6.9.3 Install the Motor (Refer to Figure 5.2)

1. Install the Motor Pinion (piece 38) and Elastic Stop Nut (piece 40) onto the motor shaft. NOTE: The elastic stop nut should not be reused. It is recommended that a new nut be used during reassembly. 2. Install conduit Nipple Flange (piece 30) and Seal (piece 42) onto the conduit nipple in the flange and secure the motor. Secure the nipple flange.

6.9.4 Lubrication Procedure

1. Set unit on mounting base. 2. Grease through the grease fitting located on the motor adapter, watch for grease entering the housing cavity. 3. Grease through the grease fitting in the housing cover until the adapter has been completely greased and grease can be seen entering the drive sleeve compartment. 4. Reposition the unit nameplate down. 5. Finish filling housing cavity through the gear limit switch opening to within 1/2 from the bottom of the gear limit switch opening.

6.9.5 Install Geared Limit Switch, Torque Switch and Finish Assembly
1. Install torque and limit switch into the switch compartment housing. NOTE: The limit switch must be reset before the actuator is placed back into service. The Torque Switch may need to be rebalanced. If required see Section 4.4.2, Balancing Torque Switch. 2. Connect all electrical leads in the switch compartment. 3. Replace the compartment cover, handwheel and thrust base, if applicable, to complete the assembly.



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Limitorque Actuation Systems L120 Series

FCD LMENIM1201-01 07/06

How to Order Parts

To order parts or obtain further information about your Limitorque L120 valve actuators, contact your local Limitorque distributor sales office, or: Flowserve Limitorque Actuation Systems 5114 Woodall Road P.O. Box 11318 Lynchburg, VA 24506-1318 Telephone (434) 528-4400 Fax (434) 845-9736 All inquiries or orders must be accompanied by the following information: 1. Actuator Size 2. Limitorque Order Number 3. Limitorque Serial Number



Limitorque Actuation Systems L120 Series

FCD LMENIM1201-01 07/06

8
Abex Road Newbury

Regulatory Information

Application of Council Directive(s) 89/336/EC; EMC Directive 89/392/EC; Machinery Directive 2003/10/EC; Airborne Noise Directive Standard(s) to which Conformity is Declared Machinery; EN 60204-1 EMC - Emissions; EN 50081-1&2, EN 55011, CFR 47 Immunity; EN 50082-1&2, IEC 801-3 & IEC 801-6 ESD; IEC 801-2 EFT/Bursts; IEC 801-4 Surge Immunity; IEC 801-5, ANSI/IEEE C62.41 Mains (power) Harmonics; MIL-STD-462, Method CSO1 & CSO2 Airborne Noise; MIL-STD-740-1, Table 1, and EN 60204 Manufacturers Name Limitorque, a division of Flowserve Corporation Manufacturers Address 5114 Woodall Road Lynchburg, VA 24502 Importers Name Limitorque International Importers Address

Model Number L120 Series Note: Tested with Limitorque products only and with standards applicable at time of tests. I, the undersigned, hereby declare that the equipment specified above conforms to the above Directive(s) and Standard(s). List as follows:

(Signature) Earnest Carey (Full Name) Manager, Product Management (Title) Flowserve Limitorque 5114 Woodall Rd., Lynchburg VA 24502 (Place) December 9, 2005 (Date)

Andy Hole (Authorized EU Representative)

Berkshire, RG14 5EY England Type & Description of Equipment Valve Actuators



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United States Limitorque 5114 Woodall Road, P.O. Box 11318 Lynchburg, VA 24506-1318 Phone: 434-528-4400 Facsimile: 434-845-9736 www.limitorque.com England Limitorque Abex Road Newbury Berkshire, RG14 5EY England Phone: 44-1-635-46999 Facsimile: 44-1-635-36034 Japan Limitorque Nippon Gear Co., Ltd. Asahi-Seimei Bldg. 4th Floor 1-11-11 Kita-Saiwai, Nishi-Ku Yokohama-Shi, (220-0004) Japan Phone: 81-45-326-2065 Facsimile: 81-45-320-5962 India Limitorque India, Ltd. 15/4, Mile Stone Mathura Road Faridabad 121002 India Phone: 91-129-2276586 Facsimile: 91-129-2277135 Australia Flowserve Australia, Pty. Ltd. 14 Dalmore Drive Scoresby, Victoria 3179 Australia Phone: 61 3 9759 3300 Facsimile: 61 3 9759 3301 Singapore Limitorque Asia, Pte., Ltd. 12, Tuas Avenue 20 Singapore 638824 Phone: 65-6868-4628 Facsimile: 65-6862-4940

FCD LMENIM1201-01 Printed in USA.

To find your local Flowserve representative: For more information about Flowserve Corporation, visit www.flowserve.com or call USA 1 800 225 6989

Flowserve Corporation has established industry leadership in the design and manufacture of its products. When properly selected, this Flowserve product is designed to perform its intended function safely during its useful life. However, the purchaser or user of Flowserve products should be aware that Flowserve products might be used in numerous applications under a wide variety of industrial service conditions. Although Flowserve can (and often does) provide general guidelines, it cannot provide specific data and warnings for all possible applications. The purchaser/user must therefore assume the ultimate responsibility for the proper sizing and selection, installation, operation, and maintenance of Flowserve products. The purchaser/user should read and understand the Installation Operation Maintenance (IOM) instructions included with the product, and train its employees and contractors in the safe use of Flowserve products in connection with the specific application. While the information and specifications contained in this literature are believed to be accurate, they are supplied for informative purposes only and should not be considered certified or as a guarantee of satisfactory results by reliance thereon. Nothing contained herein is to be construed as a warranty or guarantee, express or implied, regarding any matter with respect to this product. Because Flowserve is continually improving and upgrading its product design, the specifications, dimensions and information contained herein are subject to change without notice. Should any question arise concerning these provisions, the purchaser/user should contact Flowserve Corporation at any one of its worldwide operations or offices. 2006 Flowserve Corporation, Irving, Texas, USA. Flowserve is a registered trademark of Flowserve Corporation.

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